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How do you determine if hydraulic fluid needs to be replaced?

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Hydraulic fluid is the lifeblood of any hydraulic system. It transfers power, lubricates components, prevents corrosion, and cools the system. However, over time, hydraulic fluid can degrade due to contamination, oxidation, thermal stress, or wear. If the fluid is not replaced when needed, it can cause serious problems such as loss of performance, increased friction, component damage, or system failure. Therefore, it is important to know how to determine if hydraulic fluid needs to be replaced and how often to do it. In this article, you will learn the main signs and methods of checking hydraulic fluid condition and quality, as well as some general guidelines for fluid replacement intervals.

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Vishvender Singh

BEng ( Hons) | Industrial Engineering|Project Management| Certified Lean Six Sigma Black Belt| NPD
Caleb Kaiser

Manufacturing Engineer at Geoprobe Systems?
Leroy Dyck dyck

Business Owner at LEROY DYCK MECHANICAL

1 Visual inspection

One of the simplest ways to check hydraulic fluid condition is to look at its color, clarity, and consistency. Healthy hydraulic fluid should be clear and amber-colored, with no signs of cloudiness, foam, sludge, or sediment. If the fluid is dark, murky, milky, or has a burnt smell, it indicates contamination, oxidation, or overheating. You should also check for any leaks, cracks, or loose fittings in the hydraulic system that could cause fluid loss or ingress of air, water, or dirt. You can use a sight glass, a dipstick, or a drain plug to inspect the fluid level and appearance.

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Caleb Kaiser

Manufacturing Engineer at Geoprobe Systems?
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Hydraulic fluid should be changed every 2000 hours or every 2 years on a machine. With this being taken into consideration, you will see older hydraulic fluid turn to a darker less transparent color over that time.

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Leroy Dyck dyck

Business Owner at LEROY DYCK MECHANICAL
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one major consideration as to when hydraulic oil needs to be changed is environment. Just like the old days when we changed engine oil from summer to winter, hydraulic oil needs to be changed to match the climate . Hot summers and cold winter starts are different. Since hydraulic oil is not multi-grade, it is important to use oil suitable for the ambient temperature where the system is operating

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Vishvender Singh

BEng ( Hons) | Industrial Engineering|Project Management| Certified Lean Six Sigma Black Belt| NPD
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Visual inspection of hydraulic fluid involves checking its colour, clarity, and presence of contaminants. Fresh fluid is clear and pale yellow. If it appears dark, cloudy, or contains particles, it may need replacement. Additionally, inspect for foam or bubbles, which can indicate air contamination. A burnt or foul odour suggests degradation. Regular visual checks ensure fluid quality and prevent potential damage to hydraulic systems.

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Mohammed ElNour

Senior Mechanical Engineer at PD&MS Group | DBA, MBA, MSc, MOAR, MCIOB, PRINCE2 Agile?, PRINCE2?, KPI? MPM?, OSHA?, SFC?, SCD-F?, 6σMBB?, 6σBB?, 6σGB?, 6σYB?
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To know when to change hydraulic fluid, look for a few signs. If the fluid's colour is darker than usual or if it's cloudy, it might be dirty or contaminated. A bad smell also indicates problems. Checking the fluid level regularly is key; a drop might mean leaks. For a detailed check, send a fluid sample to a lab. They can test for dirt, water content, and if the fluid is too thick or thin. Changes in how your machinery runs, like being slower or noisier, are big red flags. Always follow the maker's advice on when to swap out the fluid. Regular checks and changes keep your system running smoothly and avoid big repair costs.

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2 Sampling and testing

Another way to check hydraulic fluid condition is to take a sample and perform a laboratory analysis or use a portable test kit. Sampling and testing can provide more accurate and detailed information about the fluid's physical and chemical properties, such as viscosity, acidity, water content, particle count, and additive concentration. These parameters can indicate the fluid's ability to perform its functions and reveal any potential issues or risks. You should follow the manufacturer's recommendations and industry standards for sampling frequency, location, procedure, and equipment.

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Vishvender Singh

BEng ( Hons) | Industrial Engineering|Project Management| Certified Lean Six Sigma Black Belt| NPD
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Sampling and testing hydraulic fluid is a critical aspect of maintenance. Periodically collect fluid samples from the system and send them to a lab for analysis. Testing can reveal contaminants, oxidation levels, and fluid degradation. Assess parameters like viscosity, acidity, and water content. Results guide decisions on fluid replacement or system adjustments. Sampling and testing provide proactive maintenance, enhancing reliability and extending the life of hydraulic systems.

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3 Monitoring and sensing

A third way to check hydraulic fluid condition is to use online monitoring and sensing devices that can measure and display various fluid parameters in real time. Monitoring and sensing can help you detect any changes or trends in the fluid condition and alert you to any abnormal or critical situations. Some of the common parameters that can be monitored and sensed include temperature, pressure, flow, level, viscosity, and contamination. You should install and calibrate the devices according to the manufacturer's instructions and system specifications.

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Jonathan Ricketts, P.E.

Engineering New Frontiers
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The first type of monitoring to be done is with your eye balls. If the hydraulic fluid is puddled on the ground, its probably not in the hoses. Replace in kind.

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4 Performance evaluation

A fourth way to check hydraulic fluid condition is to evaluate the performance of the hydraulic system and its components. Performance evaluation can help you assess the fluid's impact on the system's efficiency, reliability, and safety. Some of the signs of poor performance that could indicate fluid degradation or contamination include noise, vibration, cavitation, sluggishness, jerky movements, overheating, or loss of power. You should compare the actual performance with the expected or desired performance and identify any deviations or problems.

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Vishvender Singh

BEng ( Hons) | Industrial Engineering|Project Management| Certified Lean Six Sigma Black Belt| NPD
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Performance evaluation of hydraulic fluid involves assessing the efficiency and effectiveness of the hydraulic system. Look for signs of decreased performance, such as slower operation, increased noise, or erratic behavior. Measure the system's response time and compare it to baseline performance. Monitor temperature levels, as excessive heat can indicate fluid degradation. Regular performance evaluations help identify issues early and ensure optimal system functionality.

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5 Replacement intervals

Determining the optimal replacement interval for hydraulic fluid depends on several factors, such as the type and quality of the fluid, the operating conditions and environment, the system design and maintenance, and the manufacturer's recommendations. Generally, it is recommended to replace the fluid at least every two years or 2,000 hours of operation. However, if the system is exposed to high temperatures, pressures, loads, speeds, or contamination sources, then it should be replaced more often. Additionally, if visual inspection, sampling and testing, monitoring and sensing, or performance evaluation indicates that the fluid is degraded or contaminated beyond acceptable limits then it should be replaced immediately.

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6 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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How do you determine if hydraulic fluid needs to be replaced?

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6

1 Visual inspection

2 Sampling and testing

3 Monitoring and sensing

4 Performance evaluation

5 Replacement intervals

6 Here’s what else to consider

Mechanical Engineering

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How do you determine if hydraulic fluid needs to be replaced?

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2

3

4

5

6

1 Visual inspection

2 Sampling and testing

3 Monitoring and sensing

4 Performance evaluation

5 Replacement intervals

6 Here’s what else to consider

Mechanical Engineering

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